Yamaha R1 2004 ServiceManual
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2-23 TIGHTENING TORQUESSPEC See NOTE 2 CHASSIS TIGHTENING TORQUES ItemThreadTighteningRemarksItemsizeNmmkgftlbRemarks Upper bracket and outer tubeM8262.619 Upper bracket and steering stem nutM2811 311.382 Handlebar and outer tubeM8171.712 Handlebar and upper bracketM6131.39 Steering shaft and ring nutM30181.813See NOTE 1 Outer tube and under bracketM8232.317 Main switch and upper bracketM8262.619 Front brake master cylinder cap stopperM41.20.120.9 Front brake hose union boltsM10303.022 Front brake master cylinder and bracketM6131.39 Meter assembly and front cowling stay—1.30.130.9 Headlight and front cowling stay—0.80.080.6 Front cowling and headlight assembly—1.50.151.1 Cover 7, 8 and frameM650.53.6 Under cowling and engineM650.53.6 Windshield and front cowlingM50.40.040.3 Duct and console panelM51.30.130.9 End grip and handlebarM640.42.9 Horn bracket and under bracketM640.42.9 Coolant reservoir tank and frameM650.53.6 Engine mount front (left and right)M10454.533 Engine mount rear upperM10515.137 Engine mount rear underM10515.137 Engine mount rear adjust boltM1670.75.1 Catalyst pipe stay and frameM10444.432 Clutch cable lock nut (engine side)M870.75.1 Main frame and rear frameM10414.130 Throttle cable adjust nut (throttle body side)M650.53.6 Cover 2 and plate—0.80.080.6 Pivot shaft and nutM1810510.576 Connecting rod and frameM10444.432 Relay arm and connecting rodM10444.432 Relay arm and swingarmM10444.432 Rear shock absorber and relay armM10444.432 Rear shock absorber and upper bracketM10444.432 Upper bracket and frameM14929.267 Seal guardM670.75.1 Drive chain caseM670.75.1 Chain puller adjust nutM8161.612 Fuel tank and fuel pump assemblyM540.42.9 Fuel tank stay (front side) and frameM670.75.1 Fuel tank and fuel tank stay (front side)M670.75.1 Fuel tank stay (rear side) and rear frameM670.75.1 Side cover and fuel tankM50.40.040.3 Rider seat and frameM670.75.1 Seat lock plate and rear frameM6101.07 Side cover (rear side) and frameM540.42.9
2-24 TIGHTENING TORQUESSPEC NOTE 1: NOTE 2: NOTE 3: ItemThreadTighteningRemarksItemsizeNmmkgftlbRemarks Battery box and frameM670.75.1 Atmospheric pressure sensor and battery box—0.70.070.5 Lean angle cut-off switch and battery box—20.21.4 Foot rest bracket (front) and frameM8282.820 Foot rest bracket (rear) and frameM8282.820 Rear brake master cylinder and foot rest bracketM6181.813 Rear brake hose union boltM10303.022 Sidestand bracket and frameM10636.346 Front wheel axle shaft and boltM14919.166 Rear wheel axle nutM2415015.0109 Front brake caliper and front forkM10353.525 Front brake disc and front wheelM6181.813 Rear brake disc and rear wheelM6303.022 Rear wheel sprocket and drive hubM1010010.072 Brake caliper bleed screwM860.64.3 Front wheel axle pinch boltM8202.014See NOTE 3 1. First, tighten the ring nut to approximately 52 Nm (5.2 mkg, 38 ftlb) with a torque wrench, then loosen the ring nut completely. 2. Retighten the lower ring nut to specification. Refer to “INSTALLING THE ENGINE” in chapter 5. 1. Insert the front wheel axle from the right side and tighten it with the flange bolt from the left side to 91 Nm (9.1 mkg, 65.8 ftlb). 2. In the order from the pinch bolt 2 pinch bolt 1 pinch bolt 2, tighten each bolt to 20 Nm (2.0 mkg, 14 ftlb) without perform- ing temporary tightening. 3. Check that the end face of the axle head and the end face of the fork side are flush- mounted. If they are out of alignment, make sure to fit them by adding the external force by hand or with a plastic hammer, etc. If the end face of the axle is not parallel to the end face of the fork, align them so that one point of the axle circumference is positioned on the end face of the fork. At this stage, it can be accepted if the end face of the axle becomes partially concave to the end face of the fork. 4. In the order from the pinch bolt 4 pinch bolt 3 pinch bolt 4, tighten each bolt to 20 Nm (2.0 mkg, 14 ftlb) without perform- ing temporary tightening.
2-25 LUBRICATION POINTS AND LUBRICANT TYPESSPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Water pump impeller shaft Oil pump rotors (inner and outer) Oil pump housing Oil strainer Clutch (pull rod) Oil / water pump drive sprocket and washer Clutch (thrust plate) Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surfaceYamaha bond No.1215 Crankcase mating surfaceYamaha bond No.1215 Clutch cover (crankcase mating surface)Yamaha bond No.1215 Generator rotor cover (crankcase mating surface)Yamaha bond No.1215 Pickup rotor coverYamaha bond No.1215
2-26 LUBRICATION POINTS AND LUBRICANT TYPESSPEC EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Engine mount bolts (rear upper and lower) Relay arm, connecting rod and rear shock absorber collar Pivot shaft Swingarm pivot bearing Swingarm head pipe end, oil seal and bush Oil seal (relay arm, connecting arm and rear shock absorber) Seat lock assembly moving parts Sidestand pivoting pint and metal-to-metal moving parts Link and sidestand switch contact point Sidestand hook and spring Shift shaft joint Front wheel oil seal (right and left) Front axle shaft Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface
2-27 1Radiator fan 2Radiator 3Water pump COOLING SYSTEM DIAGRAMSSPEC EAS00033 COOLING SYSTEM DIAGRAMS
2-28 1Thermostat 2Radiator cap 3Radiator 4Oil cooler COOLING SYSTEM DIAGRAMSSPEC
2-29 ENGINE OIL LUBRICATION CHARTSPEC ENGINE OIL LUBRICATION CHART
2-30 LUBRICATION DIAGRAMSSPEC 1Intake camshaft 2Exhaust camshaft 3Oil filter cartridge 4Oil level switch EAS00034 LUBRICATION DIAGRAMS
2-31 1Intake camshaft 2Exhaust camshaft 3Crankshaft 4Oil cooler 5Oil pipe 6Oil strainer 7Oil pump 8Relief valve LUBRICATION DIAGRAMSSPEC
2-32 1Oil cooler 2Oil filter cartridge 3Oil level switch 4Oil strainer 5Oil pump 6Oil pipe LUBRICATION DIAGRAMSSPEC